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MEEF - Recycling Technologies  - previous page



EnvoFuel is a process (using the ThermoFuel system) in which scrap and waste plastics are converted into diesel fuel. The system uses liquefaction, pyrolysis and the catalytic breakdown of plastics.

The system can handle a wide variety of plastics that are currently sent to landfills. A major advantage of the process is its ability to handle unsorted, unwashed plastic and its extremely high efficiency.

An EnvoFuel plant can produce up to 9,300 litres of high-grade diesel fuel from 10 tonnes of waste plastics, with system modules ranging from 10 to 20 tonnes per day.

Larger systems can be built from these modules. Out qualifying conventional plastic recycling techniques, this means that the EnvoFuel system effortlessly processes a great variety of plastics: heavily contaminated plastics such as mulch film., agricultural plastics such as silage wrap, trickle tape and other plastics that are hard to recycle (e.g. laminates of incompatible polymers, multilayer films or polymer mixtures).

In fact, most plastics can be processed directly even if contaminated with dirt, aluminium laminates, printing inks, oil residues, etc.

Current situation of recycling of plastics 

Various methodologies have been tried and tested to process waste plastics for many years, with recycling becoming the most common method reflecting (today’s environmental requirements). Plastics that cannot be processed are handled by waste management companies by normal landfilling or incineration. 

In recent years, the building or expanding of gasifiers (most notably the levels of emissions) has become difficult due to opposition from governments and community groups with environmental concerns. 

Liquefaction of plastic is a superior method of reusing this resource. The distillate product is an excellent fuel and makes EnvoFuel one of the best, economically feasible and environmentally sensitive recycling systems in the world today.  

EnvoFuel diesels can be used in any standard diesel engine, trucks, buses, trains, boats, heavy equipment and generators. 


Pyrolysis is a process of thermal degradation in the absence of oxygen. Plastic waste is continuously treated in a cylindrical chamber and the pyrolytic gases are condensed in a specially-designed condenser system. This yields a hydrocarbon distillate comprising straight and branched chain aliphatics, cyclic aliphatics and aromatic hydrocarbons. The resulting mixture is essentially the equivalent to petroleum distillate.  

The plastic is pyrolised at 370ºC-420ºC and the pyrolysis gases are condensed in a series of condensers to give a low sulphur content distillate. The de-sulphur unit makes the process complete and turns the fuel into a “green-diesel”.

The essential steps in the pyrolysis of plastics involve:

Purging oxygen from pyrolysis chamber;

  1. Evenly heating the plastic to a narrow temperature range without excessive temperature variations;

  2. Pyrolising the plastics;

  3. Passing the gases through a catalytic converter;

  4. Managing the carbonaceous char by-product before it acts as a thermal insulator and lowers the heat transfer to the plastic;

  5. Careful condensation and fractionation of the pyrolysis vapours to produce fuels of excellent quality and consistency

EnvoSmart Technologies

Keulsveld 17a
NL-4705 RS Roosendaal

Post address
P.O. Box 1600
NL-4700 BP Roosendaal

Phone: +31 (0)165 751 761
Fax   :  +31 (0)165 751 760





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